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© Copyright Blastrac Revision (A) 12-23-04
BG-250G11 & BG-250G13
Gas Powered Concrete Grinder
Blastrac
6215 N. Aluma Valley Dr.
Oklahoma City, OK 73121
1-800-256-3440
FORWARD
ISPC/Blastrac is pleased that you have selected this Diamond Grinding System
for your surface preparation requirements. This environmentally safe, closed-
cycle, surface preparation machine has been designed and built for abrasive
blast cleaning of horizontal surfaces.
This manual has been prepared to assist the operator and the maintenance
personnel in understanding the machine so that it may be operated in the most
efficient manner and maintained in the best condition. Therefore, it is necessary
that all personnel responsible for the operation and maintenance of the machine
read the manual thoroughly. By following the instructions in this manual, this
system can be easily and effectively operated, serviced and maintained by
personnel assisted by a brief period of familiarization and training from a
Blastrac technician.
Before attempting to operate, service, or maintain the machine, the personnel
should thoroughly familiarize themselves with the physical makeup of the
machine, be familiar with the major systems of the machine, and have an
understanding of its operation.
The operating and maintenance personnel must obey all the warnings and safety
precautions posted on the side of the machine and stated throughout this
manual. Serious injury to personnel or severe damage to the equipment may
result if the warnings and precautions are not followed, or through careless
handling of this equipment.
Initial operation and maintenance must be done cautiously. Extreme care should
be taken when activating any control devices until the response of the machine
and its various components are clearly understood.
If you have any questions or problems in regard to the operation or capabilities of
this Blastrac machine, please contact:
ISPC/Blastrac
6215 Aluma Valley Drive
Oklahoma City, OK 73121
405/478-3440
800/256-3440
or your nearest Service Center.
i
INTRODUCTION
This manual has been prepared to assist the operator and maintenance
personnel in understanding the machine so that it may be operated in the safest
and most efficient manner and maintained in the best condition. Therefore, it is
necessary that all personnel responsible for the operation and maintenance of
the machine read and understand the manual.
Before attempting to operate service or maintain the machine, the personnel
should thoroughly familiarize themselves with the physical make-up of the
machine. They should be familiar with the major components of the machine and
have a general understanding of overall operations.
The operating and maintenance personnel must obey all the warnings and safety
precautions posted on the machine and stated throughout this manual. Serious
injury to personnel or severe damage to the equipment may result if the warnings
and precautions are not followed.
You will be notified of any changes that occur after this manual is printed. We
will send you manual revisions that should be inserted in the manual in
accordance with instructions that will be forwarded with them.
Receipt of Machine
Examine the shipment carefully for possible damage that might have occurred
while in transit. If any damage is noted, notify the transportation carrier
immediately and advise ISPC/Blastrac.
i
ISPC/BLASTRAC
WARRANTY POLICY
This document is to be used as a guide in determining warranty policies and
procedures for BLASTRAC products. It is to be used in determining whether a
warranty is justified and also as a procedural guide in completing a BLASTRAC
Warranty Claim form.
Warranty Responsibility:
The distributor or the end user must prepare a Machine Warranty
Information Card when the machine is delivered. Failure to comply will
make any and all warranties on this equipment null and void. Credit for
warranty repairs will be given only after receipt of the WARRANTY CLAIM
FORM, properly completed with all the required details. Submittal details
are described later in this document.
Warranty Policy:
1. Blastrac warrants its products against defects in material and
workmanship under normal and proper use for a period of one hundred
and eighty (180) days from the date of delivery; in the case of Rental
Fleet Machines, date of assignment to Rental Fleet. Such warranty is
extended only to the buyer who purchases the equipment directly from
Blastrac or its authorized distributor. This warranty does not include
expendable parts such as, but not limited to, blades, blast wheel, wear
plats, liners and seals.
2. The obligation under this warranty is strictly limited to the replacement
or repair, at Blastrac’s option, of machines and does not include the
cost of transportation, loss of operating time, or normal maintenance
services.
3. This warranty does not apply to failure occurring as a result of abuse,
misuse, negligence, corrosion, erosion, normal wear and tear,
alterations or modifications made to the machine without express
written consent of Blastrac.
4. Warranty request must be submitted in writing within thirty (30) days
after failure.
5. Written authorization to return merchandise under warranty must first
be obtained from Blastrac.
Warranty Policy (Continued)
6. Blastrac reserves the right to inspect and make the final decision on
any merchandise returned under warranty.
7. Blastrac offers no warranty with respect to accessories, including but
not limited to, engines, motors, batteries, tires and any other parts not
manufactured by us but which the original manufacturer warrants.
8. Blastrac reserves the right to make product changes or improvements
without prior notice and without imposing any obligation upon itself to
install the same on its products previously sold.
9. The above warranty conditions can only be altered by Blastrac.
Blastrac must confirm alterations in writing for each specific
transaction.
10. Blastrac reserves the right to establish specific warranty terms for used
or demo machines on an individual transaction basis. Invoices
covering such merchandise will clearly state the provisions of the
applicable warranty for each specific transaction.
11. WE DO NOT AUTHORIZE ANY PERSON, REPRESENTATIVE OR
SERVICE OR SALES OUTFIT TO MAKE ANY OTHER WARRANTY
OR TO ASSUME FOR US ANY LIABILITY IN CONNECTION WITH
THE SALE OF OUR PRODUCTS OTHER THAN THOSE
CONTAINED HEREIN.
12. UNDER NO CIRCUMSTANCES SHALL BLASTRAC BE LIABLE TO
CUSTOMER OR ANY OTHER PERSON FOR ANY DIRECT,
INCIDENTAL, OR CONSEQUENTIAL DAMAGES RESULTING FROM
THE USE OF THE PRODUCT OR ARISING OUT OF ANY BREACH
OF ANY WARRANTY OR FOR ANY SPECIAL OR CONSEQUENTIAL
DAMAGES OF ANY CHARACTER, INCLUDING WITHOUT
LIMITATIONS, DAMAGES FOR ANY LOSS OF GOODWILL, WORK
STOPPAGE, OR ANY AND ALL OTHER COMMERCIAL DAMAGES
OR LOSSES.
13. BLASTRAC MAKES NO OTHER WARRANTIES, EXPRESSED OR
IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE WITH RESPECT TO THE BLASTRAC
PRODUCTS SOLD PURSUANT THERETO.
iii
Operating Instructions BG-250G11/G13
Table of Contents
© Copyright Blastrac Revision (A) 12-23-04
Sections:
Chapter 1: Technical Data
1.1 Rating ----------------------------------------------------------------------------------------------------------- 2
1.2 Unit specifications --------------------------------------------------------------------------------------------- 2
1.3 Operating range and correct usage ----------------------------------------------------------------------- 3
1.4 Machine type design ------------------------------------------------------------------------------------------ 3
1.5 Advise for operators of the machine ---------------------------------------------------------------------- 4
Chapter 2: Safety
2.1 Warnings and symbols --------------------------------------------------------------------------------------- 6
2.2 Organizational Measures------------------------------------------------------------------------------------- 9
2.3 Personnel selection and qualification ------------------------------------------------------------------- 10
2.4 Safety precautions applicable to some operating sequences ------------------------------------- 11
2.5 Special work instructions ----------------------------------------------------------------------------------- 12
2.6 Definition of the Maintenance Mode-------------------------------------------------------------------- 14
2.7 Possible dangerous aspects of the equipment-------------------------------------------------------- 15
2.8 Electrical-------------------------------------------------------------------------------------------------------- 15
Chapter 3: General
3.1 Range of application----------------------------------------------------------------------------------------- 17
3.2 Scope of supply----------------------------------------------------------------------------------------------- 17
3.3 Description of the machine--------------------------------------------------------------------------------- 18
3.4 Operating elements------------------------------------------------------------------------------------------ 19
3.5 The tools-------------------------------------------------------------------------------------------------------- 22
3.6 Care and Maintenance-------------------------------------------------------------------------------------- 23
Chapter 4: Transport
4.1 Unit specification --------------------------------------------------------------------------------------------- 25
4.2 Manual mode of moving the machine ------------------------------------------------------------------- 25
4.3 Transport with cranes or lifts ------------------------------------------------------------------------------ 26
4.4 Transport of the machine with vehicle ------------------------------------------------------------------ 27
Chapter 5: Initial Operation
5.1 Preparation for initial operation --------------------------------------------------------------------------- 29
5.2 Initial operation------------------------------------------------------------------------------------------------ 30
Chapter 6: Operation
6.1 Operation------------------------------------------------------------------------------------------------------- 35
6.2 Switching-off the machine---------------------------------------------------------------------------------- 37
6.3 Emergency shutdown -------------------------------------------------------------------------------------- 38
6.4 Safety shutdown---------------------------------------------------------------------------------------------- 38
6.5 Restarting after a fault--------------------------------------------------------------------------------------- 38
6.6 Procedures after lengthy down time --------------------------------------------------------------------- 39
Chapter 7: Maintenance
7.1 Recommendations ------------------------------------------------------------------------------------------- 41
7.2 Maintenance and inspection list -------------------------------------------------------------------------- 42
7.3 Repairing ------------------------------------------------------------------------------------------------------- 43
7.4 Grinding disc replacement / assembly ------------------------------------------------------------------ 44
7.5 Bearing Unit --------------------------------------------------------------------------------------------------- 45
7.6 Flexible coupling---------------------------------------------------------------------------------------------- 46
7.7 The V belt drive ----------------------------------------------------------------------------------------------- 47
7.8 The driving motor--------------------------------------------------------------------------------------------- 49
7.9 Additional maintenance ------------------------------------------------------------------------------------- 50
7.10 Spare parts ---------------------------------------------------------------------------------------------------- 50
7.11 Influences on the grinding pattern------------------------------------------------------------------------ 50
Operating Instructions BG-250G11/G13
Table of Contents
© Copyright Blastrac Revision (A) 12-23-04
Chapter 8: Electrical
8.1 Directions for electrical engineering --------------------------------------------------------------------- 53
8.2 Electric circuits diagrams----------------------------------------------------------------------------------- 54
Chapter 9: Troubleshooting
9.1 Grinder troubleshooting------------------------------------------------------------------------------------- 57
9.2 Electrical troubleshooting----------------------------------------------------------------------------------- 58
Chapter 10: Spare Parts
10.1 Spare parts B-250 G11/G13------------------------------------------------------------------------------ 60
List of Figures:
Figure 3.1 – Description of the machine ------------------------------------------------------------------------------- 18
Figure 3.2 – Handgrip and Jack Stand Operating Lever ---------------------------------------------------------- 19
Figure 3.3 – Starting/ Stopping-------------------------------------------------------------------------------------------- 20
Figure 3.4 – The Tools ------------------------------------------------------------------------------------------------------ 22
Figure 4.1– Transport ------------------------------------------------------------------------------------------------------- 26
Figure 5.1 – Handgrip and Operating Lever -------------------------------------------------------------------------- 30
Figure 5.2 – Starting/ Stopping ------------------------------------------------------------------------------------------- 31
Figure 6.1 – Operation-Movement of machine ----------------------------------------------------------------------- 36
Figure 6.2 – Switching off machine -------------------------------------------------------------------------------------- 37
Figure 7.1 – Grinding disk replacement--------------------------------------------------------------------------------- 44
Figure 7.2 – Lubrication- bearing unit ----------------------------------------------------------------------------------- 45
Figure 7.3 – Flexible coupling -------------------------------------------------------------------------------------------- 46
Figure 7.4 – V- belt drive --------------------------------------------------------------------------------------------------- 47
Figure 7.5 – V- belt drive disassembly --------------------------------------------------------------------------------- 48
Figure 7.6 – Belt tension --------------------------------------------------------------------------------------------------- 49
For answers to your questions about this product, contact your local
Distribution Representative or call:
Blastrac
1-800-256-3440 or 1-405-478-3440
7 am – 6 pm, Mon-Fri (CST)
Blastrac • 6215 Aluma Valley Dr. • Oklahoma City, OK 73121 USA
?
Operating Instructions BG-250G11/G13
Technical Data November 2004
Copyright Blastrac 1 Revision (A) 12-23-04
Contents Chapter 1
1.1 Rating
1.2 Unit specifications
1.3 Operating range and correct usage
1.4 Machine type designation
1.5 Advice for operators of the machine
Operating Instructions BG-250G11/G13
Technical Data November 2004
Copyright Blastrac 2 Revision (A) 12-23-04
1.1 Rating
Unit / Designation: Blastrac Grinding machine
Machine type: BG 250G11/G13
Manufacturer:
Blastrac
6215 N. Aluma Valley Dr.
Oklahoma City, OK 73121
1.2 Unit specifications
Technical data:
Grinding Machine BG-250G11/G13
Power consumption 11HP/13HP
Connected loads 12V
Tool diameter 10 in (250 mm)
Working width 10 in (250 mm)
Dust hose connection 3 in (75 mm)
Recommended Filter unit Blastrac® Turbo-Vac II, Blastrac 1-13DC
Noise Level 78 DBA
Vibration Level < 2,5 ms²
Operating Instructions BG-250G11/G13
Technical Data November 2004
Copyright Blastrac 3 Revision (A) 12-23-04
Dimensions:
BG-250G11/G13
Length 49.25 in (1250 mm)
Width 24.50 in (620 mm)
Height 39.38 in (1000 mm)
Weight 260/271 lbs (118/123 kg)
1.3 Operating range and correct usage
The grinding machine BG-250G11/G13 is exclusively
designed to grind horizontal surfaces. The machine
may not be used for other purposes. The
manufacturer will not be liable for damage or injury
resulting from such incorrect usage. In these cases
the user assumes all risks.
1.4 Machine type designation
Machine Type – BG (Blastrac Grinder)
Working Width – 250 (mm)
Power Plant – G11 or G13 (11 HP or 13 HP Gasoline)
Operating Instructions BG-250G11/G13
Technical Data November 2004
Copyright Blastrac 4 Revision (A) 12-23-04
1.5 Advice for operators of the machine
When you use the grinding machine BG-250G11/G13 it is
p
ossible to exceed the allowed scale of sound level of 85
db(A). That sound level varies depending on the
location. If the scale of sound level reaches 85 db(A) or
more, the operators and the persons who work in the
surroundings must wear noise protection.
Pay attention that you always put down the machine on the kick
stand if not grinding. If you put down the machine on the grinding
disc, the flexible coupling will deform causing unequal wear of the
tools and increased vibration level.
Operating Instructions BG-250G11/G13
Safety November 2004
© Copyright Blastrac 5 Revision (A) 12-23-04
Contents Chapter 2
2.1 Warnings and symbols
2.2 Organisational measures
2.3 Personnel selection and qualification
2.4 Safety precautions applicable to some operating sequences
2.5 Special work instructions
2.6 Definition of the Maintenance Mode
2.7 Possible dangerous aspects of the equipment
2.8 Electrical
Operating Instructions BG-250G11/G13
Safety November 2004
© Copyright Blastrac 6 Revision (A) 12-23-04
2.1 Warnings and symbols
The following denominations and symbols are used in the Operating Instructions
to highlight areas of particular importance:
Symbol of operational safety.
In these Operating Instructions this symbol will be
shown next to safety precautions that are to be
taken in order to ensure prevention to life and injury.
Follow these instructions and take special care in
these circumstances. In addition to these
instructions, the general safety precautions and
accident prevention guidelines are also to be
followed.
Particular details regarding the economical use of
the equipment.
Operating Instructions BG-250G11/G13
Safety November 2004
© Copyright Blastrac 7 Revision (A) 12-23-04
Information, instructions and restrictions with regard
to possible risks to persons or to extensive material
damages.
Operating Instructions BG-250G11/G13
Safety November 2004
© Copyright Blastrac 8 Revision (A) 12-23-04
Warning against dangerous voltages.
Indications relating to protective devices in electrical
appliances.
Indications where consultation with the
manufacturer is required.
Instructions relating to periodic checks.
Reference to important instructions contained in the
Operating Instructions.
Operating Instructions BG-250G11/G13
Safety November 2004
© Copyright Blastrac 9 Revision (A) 12-23-04
2.2 Organisational measures
The Operating Instructions are to be kept near the location
where the machine is located and must be within reach at all
times!
In addition to the Operating Instructions, general and legal regulations regarding
accident prevention and environmental protection must be complied with and
indicated!
Such duties may for example relate to the handling of hazardous substances or
to the provision and wearing of personal protection equipment as well as
compliance with traffic regulations.
The Operating Instructions must be supplemented by instructions including the
duty to supervise and report relating to particular working practices, for
example work organisation, work procedures and personnel allocation.
Personnel entrusted with working with the machine must have read the
Operating Instructions before starting work, in particular the Safety
Instructions chapter. To read these instructions during work is too late. This
particularly applies to incidental activities such as setting up the equipment,
carrying out maintenance work or training staff to work with the machine. Read
and understand the Honda Engine Manual before using this equipment.
From time to time the working practices of the staff are to be checked regarding
awareness of safety concerns and hazards.
Personnel must tie back long hair and not wear loose clothing or jewellery
including rings. There is a risk of injury through getting stuck or being drawn into
moving machinery.
Use personnel protection equipment if necessary or required by
regulations! Take notice of all safety and hazard notices on the
machine!
All safety and hazard notices at or on the machine must be kept complete and
legible!
Operating Instructions BG-250G11/G13
Safety November 2004
© Copyright Blastrac 10 Revision (A) 12-23-04
If safety-critical changes occur to the machine or its working method, the
machine must be shut down immediately! The cause of the fault must be
established immediately!
Changes, add-ons or conversions to the machine which might impair
safety must not be undertaken without the manufacturer's
permission!
This applies in particular to the fitting and adjustment of safety devices as well as
to welding on load-bearing parts.
Spare parts must comply with the technical requirements specified by the
manufacturer. This is always guaranteed if original spare parts are used.
Intervals for recurring checks and inspections specified in these
Operating Instructions must be complied with!
To perform maintenance work correctly it is imperative to be
equipped with the proper tools for the task in question.
The location and the operation of fire extinguishers must be made
known on each building site!
Take note of the facilities for reporting and fighting fires!
2.3 Personnel selection and qualification
Fundamental duties:
Work on the machine may only be undertaken by authorized personnel.
Only trained personnel may be deployed. Note the statutory minimum age!
Specify clearly the responsibilities of personnel for operation, setting up,
servicing and maintenance work!
Make sure that only authorised personnel operate or work on the machine!
Operating Instructions BG-250G11/G13
Safety November 2004
© Copyright Blastrac 11 Revision (A) 12-23-04
Define responsibilities of the machine operator also regarding to traffic safety
regulations and empower him to decline instructions from third parties which are
not complying with the safety requirements!
Personnel being trained or made acquainted with the equipment may only be
deployed on the machine under constant supervision of an experienced
person!
Work on electrical equipment or operating materials may only be
undertaken by a skilled electrician or by trained persons under
the guidance and supervision of a skilled electrician as well as
in accordance with the electrical engineering regulations.
2.4 Safety precautions applicable to some operating sequences
Ban any method of working that impairs safety!
Some measures have to be taken in order to operate the machine in safe and
operative conditions!
Only operate the machine when all safety devices and related
safety equipment, e.g. detachable safety devices, emergency stops
and suction devices are present and working correctly.
Check the machine visually for any damage and defects at least once a day!
In the event of operational malfunctions, the machine must be shut down
immediately and secured!
Secure the work area around the machine in public areas
providing a safety distance of at least 2 m from the machine.
Faults must be immediately rectified!
Operating Instructions BG-250G11/G13
Safety November 2004
© Copyright Blastrac 12 Revision (A) 12-23-04
Carry out the switch on and off operations and pay attention to control display
according to the operation manual!
Before switching on the machine make sure that no-one can be endangered
when the machine starts up!
Do not switch off or remove the exhaust and ventilation devices when the
machine is running!
All persons in the proximity of the machine, when it is working,
must wear ear protection and safety shoes. The operator is obliged
to wear close-fitting protective clothing.
Use only extension cable for extending the main cable that are
sized and marked in accordance with the overall power
consumption of the machine and the valid NEC guidelines.
2.5 Special work instructions
Mechanical servicing work:
Put the machine in the Maintenance Mode as described in chapter
2.6 for any servicing work on the machine.
Read and understand the Honda Engine Operating Manual before operating or
maintaining this machine.
Gasoline is extremely flammable. Never expose the machine to a
spark, open flame, high heat source, etc. that may present a fire
hazard.
Please follow any special safety instructions in the various chapters on
servicing the machine.
See chapter 7.1 - 7.9.
Operating Instructions BG-250G11/G13
Safety November 2004
© Copyright Blastrac 13 Revision (A) 12-23-04
Adjustment, servicing and inspection work and time limits specified in these
Operating Instructions, as well as any information on the replacement of parts
and equipment must be undertaken and/or complied with!
These activities may only be undertaken by qualified personnel.
The operator has to be familiar with the maintenance work before starting the
process!
If the equipment is switched off in order to do maintenance, repair or adjustment
it has to be secured against unintended restart. Machine must be in
Maintenance Mode as described in Chapter 2.6 before servicing.
Switch OFF and disconnect it from the power supply and secure the main
switch with a padlock.
See Chapter 2.6 Maintenance Mode for specific details.
Always dispose of the contents of the dust bin of a possible connected dust
collector used before loading it on van or truck. Observe the waste disposal
regulations; if uncertain situation ask your supervisor.
Do not use any aggressive cleaning materials!
Use lint-free cleaning cloths!
Always tighten any screw connections that are undone during servicing and
maintenance work!
If safety devices need to be taken off or dismantled during service and repair,
these safety devices must be reinstalled and inspected immediately after
completion of the servicing and repair work.
Make sure that process materials and replaced parts are disposed of safely
and in an environmentally-friendly manner!
Work on electrical equipment or operating materials may only be
undertaken by a skilled electrician or by trained persons under
the guidance and supervision of a skilled electrician as well as
in accordance with the electrical engineering regulations.
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